US10926465B2 - Recoater for additive layer manufacture - Google Patents

Recoater for additive layer manufacture Download PDF

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Publication number
US10926465B2
US10926465B2 US15/927,268 US201815927268A US10926465B2 US 10926465 B2 US10926465 B2 US 10926465B2 US 201815927268 A US201815927268 A US 201815927268A US 10926465 B2 US10926465 B2 US 10926465B2
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Prior art keywords
layer
outlet
doctor blade
tip
doctor blades
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US20180272604A1 (en
Inventor
Stewart T. WELCH
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Rolls Royce PLC
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Rolls Royce PLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/214—Doctor blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/02—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
    • B05C11/04—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface with blades
    • B05C11/045—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface with blades characterised by the blades themselves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/02—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
    • B05C11/06—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface with a blast of gas or vapour
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing

Definitions

  • the present disclosure relates to additive layer manufacturing methods and apparatus. More particularly, the present disclosure concerns a re-coater device (sometimes known as a “doctor blade”) for use in an additive layer manufacturing method.
  • a re-coater device sometimes known as a “doctor blade”
  • additive layer manufacturing methods are known. Broadly, such methods involve selected regions within a fluid mass of material being processed across a number of sequential layers to cause local solidification of the material. The sequential layers are built up to form a three dimensional solid object within the fluid mass.
  • the process starts with a bulk mass which may, for example, be a bed of powdered material such as a ceramic, a ferrous alloy or a non-ferrous alloy, or a vat of liquid typically comprising a photopolymer. Regions within the mass are selectively treated, for example by melting, sintering, photochemical reaction or interaction with a chemical bonding agent, to solidify.
  • the untreated material remains in a layer as the next layer is formed.
  • Surplus (untreated) material may be removed when the three dimensional build is complete, through it is also known for surplus material sometimes to be contained within cavities of the three-dimensional object.
  • a layer of untreated material may be deposited onto an already treated layer by dispersal from a hopper or by dipping the treated layer below the surface of the untreated material.
  • the thickness and consistency of thickness of each layer to be treated must be carefully controlled. This is conventionally achieved by positioning a top surface a fixed distance from the tip of a “doctor blade” which is then skimmed across a top surface of the material to level out the top surface.
  • doctor blade In its simplest form the doctor blade is a straight-edged, rigid blade which is skimmed across the material surface gradually pushing away any excess from the newly added material layer.
  • the straight edged, rigid blade may comprise a hollow through which a vacuum can be applied. The blade is positioned a small distance from the required top surface level. Rather than push material away, such a device sucks excess material into the hollow as it passes across the surface. In regions where there is insufficient material remaining at the top surface, the vacuum effect is arrested and material is drawn from the hollow back onto the surface.
  • the material to be treated is viscous
  • the air supply may be a compressed air supply.
  • the apparatus may further include a flow control device adjustable to vary the velocity and or pressure of the directed air supply.
  • the apparatus may further include a temperature control device for adjusting and or maintaining the temperature of the compressed air supply.
  • the blade may include features downstream of the outlet configured to control and/or direct air exiting the outlet. Without limitation, such features may include a grid, one or more nozzles, differently directed channels or the like. In an option, the blade tip may be tapered to provide a converging or diverging outlet.
  • multiple doctor blades are provided.
  • individual blades of the multiple doctor blades may have a different configuration to others of the multiple doctor blades.
  • multiple blades may have the same structure but air supply to each is individually controllable.
  • individual blades may have individual supply lines and any given supply line may include a flow control device which is adjustable independently of a flow control device in another supply line.
  • the doctor blade may be flexible.
  • the doctor blade may have an associated flexible element arranged to follow the tip of the doctor blade across the material layer to be recoated.
  • the flexible doctor blade or flexible element may be configured to flex when drawn across the material layer in a first direction but inflexible when drawn across the material layer in a second direction which is opposite to the first direction.
  • the apparatus may include a build platform in an X-Y plane and an indexing device for moving the blade in a direction Z, orthogonal to the X-Y plane.
  • the apparatus may include a build platform in an X-Y plane and an indexing device for moving the build platform in a direction Z, orthogonal to the X-Y plane.
  • the additive layer manufacturing apparatus may include a container for a powdered material from which a 3 dimensional product is to be built and a device for initiating fusion of the powder.
  • the device for initiating fusion of the powder may, for example, be a laser or an electron beam.
  • FIG. 1 shows a first known additive layer manufacturing apparatus suited to the building of a three dimensional product by photo-polymerisation of a liquid resin
  • FIG. 2 shows the apparatus of FIG. 1 immediately after the build platform has been raised and before the doctor blade has been swept across the build platform;
  • FIG. 3 shows a second known additive layer manufacturing apparatus which employs a vacuum doctor blade
  • FIG. 4 shows the apparatus of FIG. 3 during a sweep of the vacuum doctor blade in a first direction
  • FIG. 5 shows an additive layer manufacturing apparatus in accordance with an embodiment of the present disclosure
  • FIG. 6 shows the additive layer manufacturing apparatus of FIG. 5 midway during a sweep of the doctor blade
  • FIG. 7 shows a first modification of a doctor blade in accordance with the present disclosure
  • FIG. 8 shows a second modification of a doctor blade in accordance with the present disclosure
  • FIG. 9 shows a third modification of a doctor blade in accordance with the present disclosure.
  • FIG. 10 shows a fourth modification of a doctor blade in accordance with the present disclosure.
  • an additive layer manufacturing apparatus comprises a vat 1 for containing a resin 2 .
  • a light source 3 is arranged to selectively focus on regions within layers of the resin 2 to initiate photo-polymerisation and build a 3 dimensional body of which a first layer 4 is shown.
  • the first layer 4 is built on a build platform 5 which can be moved an upward and downward as represented by the two headed arrow beneath the build platform 5 in the Figure.
  • the figure shows the top of the layer 4 just below the surface of the resin 6 .
  • the surface of the resin is substantially flat. This is typical at commencement of the additive layer manufacture and at a point where movement of the platform 5 has been arrested for some time.
  • To build a second layer on to the first layer 4 the platform 5 is dropped into the resin 2 and then raised back to a surface level. This is sometimes termed “deep dipping”.
  • FIG. 2 illustrates the apparatus of FIG. 1 immediately after deep dipping.
  • a second layer 9 sits on top surface 4 a of the first layer 4 . Due to viscosity and surface tension in the resin 2 a mound 8 of resin is formed on the surface 9 a of the second layer 9 . There then follows a waiting period while resin the mound 8 redistributes forming a flatter layer. Where the resin 2 is highly viscous, this can significantly delay the manufacture a body.
  • the doctor blade 7 can be swept across the surface 6 to level the mound 8 , however, when the build is only a few layers thick, this sweeping motion has an associated risk of stressing the build with a consequence of possible structural damage to the body.
  • the vacuum doctor blade 37 is characterised by a cavity 30 extending from a tip 31 of the blade.
  • the cavity 30 is connected to a suction device which removes air from the cavity 30 (as represented by the grey arrow above the blade) creating a vacuum effect at the tip 31 .
  • the tip 31 of vacuum doctor blade 37 is spaced a small distance d from the surface 36 of the resin 32 . The distance is typically less than the thickness of a build layer. Since the tip is not directly contacting the surface 36 , stress on the build is reduced compared to the arrangement of FIGS. 1 and 2 .
  • the vacuum doctor blade 37 has just made a pass over layer 39 .
  • the surface 39 a of the already formed layer 39 is lowered beneath the resin surface 36 by a distance equating to the desired layer thickness.
  • a dip 40 results in the resin surface 36 .
  • the vacuum doctor blade 37 is swept in a reverse direction back over the surface layer 36 .
  • suction to the cavity 30 is ceased and consequently, as the tip 31 passes over dip 40 , resin is released from the cavity 30 into the dip 40 .
  • Excess resin is now left on the surface 39 a due to the stand-off height between the vacuum doctor blade 37 and the resin surface 36 . This then requires a wait time to drain back off the surface 39 a of the already formed layer 39 .
  • FIG. 5 illustrates an embodiment of an additive layer manufacturing apparatus in accordance with the present disclosure.
  • the apparatus is shown at a point in the manufacture when a recently polymerised layer 59 has just been dipped in the resin 52 and raised back to the resin surface level 56 in a similar manner as described in relation to FIG. 2 .
  • a mound 58 is formed on the surface 59 a of the polymerised layer 59 .
  • the vacuum blade of this apparatus has a cavity 50 passing through the doctor blade 57 .
  • the cavity has an outlet at a tip 51 of the doctor blade 57 .
  • a conduit 60 connects the cavity 50 to an air supply 53 which forces air through the conduit 60 and the cavity 50 towards the surface 56 of the resin.
  • the tip 51 of the blade is positioned a small distance d from the surface level 56 of the resin 52 such that there is no direct contact between the two.
  • FIGS. 7, 8 and 9 illustrate optional adaptations of the tip 51 to control flow of air exiting at the tip 51 .
  • FIG. 7 shows a section and an end view of a first optional adaptation of the doctor blade.
  • the cavity 50 has convergent walls 61 towards the tip 51 resulting in a narrowed slot 62 in the tip.
  • FIG. 8 shows a section and an end view of a second optional adaptation of the doctor blade. As can be seen the tip 51 end of the cavity 50 is covered by a grid 63 .
  • FIG. 9 shows a section and an end view of a third optional adaptation of the doctor blade.
  • the tip 51 comprises a wall through which differently directed channels 64 , 65 are provided.
  • FIG. 10 shows a section and an end view of a fourth optional adaptation of the doctor blade.
  • the doctor blade 57 of this embodiment includes a follow blade 66 on one side of the doctor blade 57 .
  • the follower blade 66 is flexible as represented by the dotted outline and curved arrow in the Figure. When in its resting state, a tip of the flexible follower blade 66 extends beyond the tip 51 of the of the doctor blade 57 by a distance d. In use, whilst the tip 51 of the doctor blade 57 does not contact the surface of the resin, the tip of the follow blade contacts the surface of the resin. As the follow blade 66 is swept across the surface, it flexes thereby reducing stress on the surface layer.
  • doctor blade 57 and associated air supply 53 may also be used to fill efficiently a dip in a resin surface.
  • the apparatus of the present disclosure may be applied to other additive layer manufacturing methods, for example powder bed ALM.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
US15/927,268 2017-03-24 2018-03-21 Recoater for additive layer manufacture Active US10926465B2 (en)

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Application Number Priority Date Filing Date Title
GBGB1704676.4A GB201704676D0 (en) 2017-03-24 2017-03-24 Recoater for additive layer manufature
GB1704676.4 2017-03-24

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Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4397425A3 (de) * 2018-12-20 2024-08-14 Concept Laser GmbH Baumaterialhandhabungseinheit für ein pulvermodul für eine vorrichtung zur generativen fertigung eines dreidimensionalen objekts
WO2022051222A1 (en) 2020-09-04 2022-03-10 Vulcanforms Inc. Defect mitigation for recoating systems for additive manufacturing
DE102020125403A1 (de) 2020-09-29 2022-03-31 Mühlbauer Technology Gmbh 3D-Drucker und dessen Verwendung
US11110650B1 (en) * 2020-10-02 2021-09-07 Intrepid Automation Vat-based additive manufacturing with dispensed material
US11772162B2 (en) * 2020-10-29 2023-10-03 GM Global Technology Operations LLC Local collection of contaminants formed during metal powder bed fusion process
CN115157665B (zh) * 2022-09-08 2022-12-06 季华实验室 基于气刀的连续3d打印方法及装置

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US4331099A (en) * 1979-09-24 1982-05-25 Hoechst Aktiengesellschaft Metering device for lacquer
EP0361847A2 (de) 1988-09-26 1990-04-04 3D Systems, Inc. Auftragen von stereolithographischen Schichten
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US20180272604A1 (en) 2018-09-27
EP3378629A1 (de) 2018-09-26
EP3378629B1 (de) 2020-04-22
GB201704676D0 (en) 2017-05-10

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